Analyte Sensors Comprising High-Boiling Point Solvents

ABSTRACT

Generally, embodiments of the present disclosure relate to analyte determining methods and devices (e.g., electrochemical analyte monitoring systems) that have improved uniformity of distribution of the sensing layer by inclusion of a high-boiling point solvent, where the sensing layer is disposed proximate to a working electrode of in vivo and/or in vitro analyte sensors, e.g., continuous and/or automatic in vivo monitoring using analyte sensors and/or test strips. Also provided are systems and methods of using the, for example electrochemical, analyte sensors in analyte monitoring.

INTRODUCTION

In many instances it is desirable or necessary to regularly monitor theconcentration of particular constituents in a fluid. A number of systemsare available that analyze the constituents of bodily fluids such asblood, urine and saliva. Examples of such systems conveniently monitorthe level of particular medically significant fluid constituents, suchas, for example, cholesterol, ketones, vitamins, proteins, and variousmetabolites or blood sugars, such as glucose. Diagnosis and managementof patients suffering from diabetes mellitus, a disorder of the pancreaswhere insufficient production of insulin prevents normal regulation ofblood sugar levels, requires carefully monitoring of blood glucoselevels on a daily basis. A number of systems that allow individuals toeasily monitor their blood glucose are currently available. Such systemsinclude electrochemical biosensors, including those that comprise aglucose sensor that is adapted for insertion into a subcutaneous sitewithin the body for the continuous monitoring of glucose levels inbodily fluid of the subcutaneous site (see for example, U.S. Pat. No.6,175,752 to Say et al).

A person may obtain a blood sample by withdrawing blood from a bloodsource in his or her body, such as a vein, using a needle and syringe,for example, or by lancing a portion of his or her skin, using a lancingdevice, for example, to make blood available external to the skin, toobtain the necessary sample volume for in vitro testing. The person maythen apply the fresh blood sample to a test strip, whereupon suitabledetection methods, such as calorimetric, electrochemical, or photometricdetection methods, for example, may be used to determine the person'sactual blood glucose level. The foregoing procedure provides a bloodglucose concentration for a particular or discrete point in time, andthus, must be repeated periodically, in order to monitor blood glucoseover a longer period.

In addition to the discrete or periodic, in vitro, bloodglucose-monitoring systems described above, at least partiallyimplantable, or in vivo, blood glucose-monitoring systems, which areconstructed to provide continuous in vivo measurement of an individual'sblood glucose concentration, have been described and developed.

Such analyte monitoring devices are constructed to provide forcontinuous or automatic monitoring of analytes, such as glucose, in theblood stream or interstitial fluid. Such devices include electrochemicalsensors, at least a portion of which are operably positioned in a bloodvessel or in the subcutaneous tissue of a user.

While continuous glucose monitoring is desirable, there are severalchallenges associated with optimizing manufacture protocols to improveyield and uniformity of the sensing layer of the biosensors constructedfor in vivo use. Accordingly, further development of manufacturingtechniques and methods, as well as analyte-monitoring devices, systems,or kits employing the same, is desirable.

SUMMARY

Generally, embodiments of the present disclosure relate to analytedetermining methods and devices (e.g., electrochemical analytemonitoring systems) that have improved uniformity of distribution of thesensing layer by inclusion of a high-boiling point solvent, where thesensing layer is disposed proximate to a working electrode of in vivoand/or in vitro analyte sensors, e.g., continuous and/or automatic invivo monitoring using analyte sensors and/or test strips. Also providedare systems and methods of using the, for example electrochemical,analyte sensors in analyte monitoring.

BRIEF DESCRIPTION OF THE DRAWINGS

A detailed description of various embodiments of the present disclosureis provided herein with reference to the accompanying drawings, whichare briefly described below. The drawings are illustrative and are notnecessarily drawn to scale. The drawings illustrate various embodimentsof the present disclosure and may illustrate one or more embodiment(s)or example(s) of the present disclosure in whole or in part. A referencenumeral, letter, and/or symbol that is used in one drawing to refer to aparticular element may be used in another drawing to refer to a likeelement.

FIG. 1 shows a block diagram of an embodiment of an analyte monitoringsystem according to embodiments of the present disclosure.

FIG. 2 shows a block diagram of an embodiment of a data processing unitof the analyte monitoring system shown in FIG. 1.

FIG. 3 shows a block diagram of an embodiment of the primary receiverunit of the analyte monitoring system of FIG. 1.

FIG. 4 shows a schematic diagram of an embodiment of an analyte sensoraccording to the embodiments of the present disclosure.

FIGS. 5A-5B show a perspective view and a cross sectional view,respectively, of an embodiment an analyte sensor.

FIGS. 6A-6B show a microphotograph and a profilometer graph,respectively, of a control spot of a sensing layer formulation on a goldsurface. FIG. 6A shows a thick, dark outer ring encircling the spot thatrepresents the formation of the “coffee ring” effect referred to herein.FIG. 6B shows a profilometer graph, which shows a cross-sectionalprofile of the spot of the sensing layer and illustrates the formationof the “coffee ring” effect referred to herein.

FIGS. 7A-7B show a microphotograph and profilometer graph, respectively,of a spot of a sensing layer formulation on a gold surface, where thesensing layer formulation included 5% (w/v) ethylene glycol. Themicrophotograph and profilometer graph illustrate the extent ofhomogeneity, and uniformity of solution distribution that resulted whena high-boiling point solvent was added to the sensing layer formulation.

FIGS. 8A-8B show a microphotograph and profilometer graph, respectively,of a spot of a sensing layer formulation on a gold surface, where thesensing layer formulation included 15% (w/v) ethylene glycol. Themicrophotograph and profilometer graph illustrate the extent ofhomogeneity, and uniformity of solution distribution that resulted whena high-boiling point solvent was added to the sensing layer formulation.

FIGS. 9A-9B show a microphotograph and profilometer graph, respectively,of a spot of a sensing layer formulation on a gold surface, where thesensing layer formulation included 3% (w/v) diethylene glycol monomethylether. The microphotograph and profilometer graph illustrate the extentof homogeneity, and uniformity of solution distribution that resultedwhen a high-boiling point solvent was added to the sensing layerformulation.

FIGS. 10A-10B show a microphotograph and profilometer graph,respectively, of a spot of a sensing layer formulation on a goldsurface, where the sensing layer formulation included 20% (w/v)diethylene glycol monomethyl ether. The microphotograph and profilometergraph illustrate the extent of homogeneity, and uniformity of solutiondistribution that resulted when a high-boiling point solvent was addedto the sensing layer formulation.

FIGS. 11A-11B show a microphotograph and profilometer graph,respectively, of a spot of a sensing layer formulation on a goldsurface, where the sensing layer formulation included 5% (w/v) dimethylsulfoxide. The microphotograph and profilometer graph illustrate theextent of homogeneity, and uniformity of solution distribution thatresulted when a high-boiling point solvent was added to the sensinglayer formulation.

FIGS. 12A-12D show microphotographs of spots of sensing layerformulations that included 5% (w/v) diethylene glycol monomethyl ether(FIG. 12A), 10% (w/v) diethylene glycol monomethyl ether (FIG. 12B), 15%(w/v) diethylene glycol monomethyl ether (FIG. 12C), and 20% (w/v)diethylene glycol monomethyl ether (FIG. 12D). The microphotographsillustrate the extent of homogeneity, and uniformity of solutiondistribution that resulted when a high-boiling point solvent was addedto the sensing layer formulation.

FIGS. 13A-13B show a microphotograph and profilometer graph,respectively, of a spot of a sensing layer formulation on a goldsurface, where the sensing layer formulation included 1% (w/v) ethyleneglycol. FIGS. 13C-13D show a microphotograph and profilometer graph,respectively, of a spot of a sensing layer formulation on a goldsurface, where the sensing layer formulation included 3% (w/v) ethyleneglycol. The microphotographs and profilometer graphs illustrate theextent of homogeneity, and uniformity of solution distribution thatresulted when a high-boiling point solvent was added to the sensinglayer formulation.

FIGS. 14A-14B show a microphotograph and profilometer graph,respectively, of a spot of a sensing layer formulation on a goldsurface, where the sensing layer formulation included 1% (w/v)diethylene glycol monomethyl ether. The microphotograph and profilometergraph illustrate the extent of homogeneity, and uniformity of solutiondistribution that resulted when a high-boiling point solvent was addedto the sensing layer formulation.

FIGS. 15A-15B show a microphotograph and profilometer graph,respectively, of a spot of a sensing layer formulation on a goldsurface, where the sensing layer formulation included 1% (w/v) dimethylsulfoxide. FIGS. 15C-15D show a microphotograph and profilometer graph,respectively, of a spot of a sensing layer formulation on a goldsurface, where the sensing layer formulation included 3% (w/v) dimethylsulfoxide. The microphotographs and profilometer graphs illustrate theextent of homogeneity, and uniformity of solution distribution thatresulted when a high-boiling point solvent was added to the sensinglayer formulation.

FIGS. 16A-16C show microphotographs of spots of sensing layerformulations on a gold surface. FIG. 16A shows a microphotograph of asensing layer formulation that included 5% (w/v) ethylene glycol. FIG.16B shows a microphotograph of a spot of a sensing layer formulationthat included 5% (w/v) diethylene glycol monomethyl ether. FIG. 16Cshows a microphotograph of a spot of a sensing layer formulation thatincluded 5% (w/v) dimethyl sulfoxide. The microphotographs andprofilometer graphs illustrate the extent of homogeneity, and uniformityof solution distribution that resulted when a high-boiling point solventwas added to the sensing layer formulation.

FIG. 17 shows graphs of sensitivity/slope (nA/mM) for sensing layerformulations that included varying concentrations of high-boiling pointsolvents, e.g., 5% (w/v) ethylene glycol, 15% (w/v) ethylene glycol, 5%(w/v) diethylene glycol monomethyl ether, and 15% (w/v) diethyleneglycol monomethyl ether.

FIG. 18 shows graphs of average response time (sec) for sensing layerformulations that included varying concentrations of high-boiling pointsolvents, e.g., 5% (w/v) ethylene glycol, 15% (w/v) ethylene glycol, 5%(w/v) diethylene glycol monomethyl ether, and 15% (w/v) diethyleneglycol monomethyl ether.

DETAILED DESCRIPTION

Before the embodiments of the present disclosure are described, it is tobe understood that this invention is not limited to particularembodiments described, as such may, of course, vary. It is also to beunderstood that the terminology used herein is for the purpose ofdescribing particular embodiments only, and is not intended to belimiting, since the scope of the embodiments of the invention will belimited only by the appended claims.

Where a range of values is provided, it is understood that eachintervening value, to the tenth of the unit of the lower limit unlessthe context clearly dictates otherwise, between the upper and lowerlimits of that range is also specifically disclosed. Each smaller rangebetween any stated value or intervening value in a stated range and anyother stated or intervening value in that stated range is encompassedwithin the invention. The upper and lower limits of these smaller rangesmay independently be included or excluded in the range, and each rangewhere either, neither or both limits are included in the smaller rangesis also encompassed within the invention, subject to any specificallyexcluded limit in the stated range. Where the stated range includes oneor both of the limits, ranges excluding either or both of those includedlimits are also included in the invention.

In the description of the invention herein, it will be understood that aword appearing in the singular encompasses its plural counterpart, and aword appearing in the plural encompasses its singular counterpart,unless implicitly or explicitly understood or stated otherwise. Merelyby way of example, reference to “an” or “the” “analyte” encompasses asingle analyte, as well as a combination and/or mixture of two or moredifferent analytes, reference to “a” or “the” “concentration value”encompasses a single concentration value, as well as two or moreconcentration values, and the like, unless implicitly or explicitlyunderstood or stated otherwise. Further, it will be understood that forany given component described herein, any of the possible candidates oralternatives listed for that component, may generally be usedindividually or in combination with one another, unless implicitly orexplicitly understood or stated otherwise. Additionally, it will beunderstood that any list of such candidates or alternatives, is merelyillustrative, not limiting, unless implicitly or explicitly understoodor stated otherwise.

Various terms are described below to facilitate an understanding of theinvention. It will be understood that a corresponding description ofthese various terms applies to corresponding linguistic or grammaticalvariations or forms of these various terms. It will also be understoodthat the invention is not limited to the terminology used herein, or thedescriptions thereof, for the description of particular embodiments.Merely by way of example, the invention is not limited to particularanalytes, bodily or tissue fluids, blood or capillary blood, or sensorconstructs or usages, unless implicitly or explicitly understood orstated otherwise, as such may vary.

The publications discussed herein are provided solely for theirdisclosure prior to the filing date of the application. Nothing hereinis to be construed as an admission that the embodiments of the inventionare not entitled to antedate such publication by virtue of priorinvention. Further, the dates of publication provided may be differentfrom the actual publication dates which may need to be independentlyconfirmed.

Systems and Methods Using High-Boiling Point Solvents

Embodiments of the present disclosure relate to methods and devices forimproving the uniformity of distribution of one or more components of asensor by inclusion of a high-boiling point solvent, where thecomponents are disposed proximate to a working electrode of the sensor,such as in vivo and/or in vitro analyte sensors, including, such as,continuous and/or automatic in vivo analyte sensors. For example,embodiments of the present disclosure provide for inclusion of ahigh-boiling point solvent in a solution, such as a sensing layerformulation, resulting in an increase in the boiling point of thesolution, thereby reducing the rate of evaporation. Also provided aresystems and methods of using the analyte sensors in analyte monitoring.

In general, embodiments of the present disclosure are based on thediscovery that the addition of a high-boiling point solvent to solutionformulations used in the manufacture of in vivo and/or in vitrobiosensors improves uniformity and/or distribution of one or morecomponents of the sensor (e.g., an enzyme-containing sensing layer).High-boiling point solvents are solvents that have a boiling point of120° C. or greater, such as 150° C. or greater, such as 170° C. orgreater, including 190° C. or greater, for example 200° C. or greater,or 250° C. or greater, such as 300° C. or greater.

During the manufacturing process for the subject analyte sensors, anaqueous solution (e.g., a sensing layer) is contacted with a surface ofa substrate (e.g., a surface of a working electrode), forming adeposition of the solution on the surface of the substrate. In somecases, the solution is allowed to dry and cure. Without being limited toany particular theory, in certain instances, during the drying, theconstituents of the solution may tend to migrate towards the outer edgesof the deposition due to a faster rate of evaporation at the thinnerperipheral edges of the deposition. This results in a greaterconcentration of the constituents of the solution at the peripheraledges of the deposition, resulting in a so-called “coffee ring” effect.

In certain embodiments of the present disclosure, the high-boiling pointsolvents decrease the rate of evaporation of the solution by raising theboiling point of the solution. This may result in a reduction and insome cases complete elimination of the “coffee ring” effect (see e.g.,the homogenous and uniform distribution of each sample in FIGS. 7A-7B,FIGS. 8A-8B, FIGS. 9A-9B, FIGS. 10A-10B, FIGS. 11A-11B, FIGS. 12A-12D,FIGS. 13A-13D, FIGS. 14A-14B, FIGS. 15A-15D, and FIGS. 16A-16C). In somecases, this results in a more uniform distribution of the constituentsof the solution deposited on the substrate upon drying and curing ascompared to a solution lacking the high-boiling point solvent. In someinstances, this also results in a smoother surface of the solution upondrying and curing as compared to a solution lacking the high-boilingpoint solvent. This, in turn, improves the coefficient of variation andthe overall manufacturing process of the sensor and overall system.

In certain embodiments, when solutions including the high-boiling pointsolvents of the present disclosure are deposited on the surface of asubstrate, the resulting deposition has a substantially arcuate profileas measured using a profilometer (see e.g., FIG. 7B, FIG. 8B, FIG. 11B,and FIG. 15D). By arcuate is meant that a cross-sectional profile of thedeposition has a curved or rounded shape, e.g., an arc shape. Incomparison, depositions exhibiting the “coffee ring” effect havecross-sectional profiles that may include more than one local maximaand/or local minima (i.e., peaks and valleys; see e.g., FIG. 6B). Forexample, depositions having a “coffee ring” effect may have profilesthat include local maxima near the peripheral edges of the depositionand a local minimum therebetween. In certain embodiments, solutionsincluding a high-boiling point solvent have a reduction in the “coffeering” effect as compared to a control solution that does not include ahigh-boiling point solvent (see e.g., FIG. 9B, FIG. 10B, FIG. 13B, FIG.13D, FIG. 14B, and FIG. 15B as compared to control FIG. 6B).

Examples of high-boiling point solvents suitable for use with thesubject methods, compositions and kits include, but are not limited to,bivalent alcohols, bivalent alcohol alkyl ethers, bivalent alcoholdialkyl ethers, and polar aprotic solvents. Examples of bivalentalcohols that may find use in the present disclosure include, but arenot limited to, ethylene glycol, diethylene glycol, propylene glycol,1,4-butanediol, 1,3-propanediol, mixtures thereof, and the like.Examples of bivalent alcohol alkyl ethers include, but are not limitedto, diethylene glycol monomethyl ether, ethylene glycol monomethylether, ethylene glycol monoethyl ether, ethylene glycol monopropylether, ethylene glycol monoisopropyl ether, ethylene glycol monobutylether, ethylene glycol monophenyl ether, ethylene glycol monobenzylether, diethylene glycol monoethyl ether, diethylene glycol mono-n-butylether, mixtures thereof, and the like. Examples of bivalent alcoholdialkyl ethers include, but are not limited to, diethylene glycoldimethyl ether, ethylene glycol dimethyl ether, ethylene glycol diethylether, ethylene glycol dibutyl ether, diethylene glycol diethyl ether,mixtures thereof, and the like. Examples of polar aprotic solventsinclude, but are not limited to dimethyl sulfoxide,dimethyl-2-imidazolidinone, N-methyl-2-pyrrolidone, mixtures thereof,and the like.

In certain embodiments, the high-boiling point solvent includes ethyleneglycol, diethylene glycol monomethyl ether, diethylene glycol dimethylether, dimethyl sulfoxide, or combinations thereof. The boiling pointsof the high-boiling point solvents of certain embodiments are shown inTable 1 below.

TABLE 1 High-Boiling Point Solvent Boiling Point ethylene glycol195-197° C. diethylene glycol monomethyl ether 190-194° C. diethyleneglycol dimethyl ether 162° C. dimethyl sulfoxide 189° C.

The high-boiling point solvent may be included in any component of asensor that can benefit from improvement of the uniformity ofdistribution of the constituents of a solution deposited on a surface ofa substrate. Embodiments include, but are not limited to, formulationsthat provide reagents such as enzyme or the like, such as a sensinglayer having an analyte responsive enzyme. Such components may besensitive to the formation of crinkles and creases upon curing, givingan “orange peel” effect, such that the surface of the layer may resemblean orange peel. In addition, the component formulation of a sensor whencontacted to the sensor (e.g., by dip coating, spray coating, dropdeposition, and the like) and cured may form a brittle shell. Thisphenomenon may give the device a brittleness that may cause it to crack,break down and/or peel off of the substrate. These characteristics maycause the sensing layer to slough, chip and peel off carbon substratesand other substrates. In some instances, this chipping can result in theundesirable deposition of residual pieces of the sensing layer in vivo.In addition, the components of a solution are also sensitive tomigrating and settling along the outer perimeter of the deposition,referred to as formation of a “coffee ring” effect on the substrate.

Additional embodiments of a sensor that may be suitably formulated witha high-boiling point solvent are described in U.S. Pat. Nos. 5,262,035,5,262,305, 6,134,461, 6,143,164, 6,175,752, 6,338,790, 6,579,690,6,654,625, 6,736,957, 6,746,582, 6,932,894, 6,605,200, 6,605,201,7,090,756, 6,746,582 as well as those described in U.S. patentapplication Ser. Nos. 11/701,138, 11/948,915, all of which areincorporated herein by reference in their entirety.

In some embodiments, the high-boiling point solvent is formulated with asensing layer that is disposed proximate to the working electrode.Generally, an embodiment of a sensing layer may be described as the areashown schematically in FIG. 5B as 508. The sensing layer may bedescribed as the active chemical area of the biosensor. The sensinglayer formulation, which can include a glucose-transducing agent, mayinclude, for example, among other constituents, a redox mediator, suchas, for example, a hydrogen peroxide or a transition metal complex, suchas a ruthenium-containing complex or an osmium-containing complex, andan analyte response enzyme, such as, for example, a glucose responsiveenzyme (e.g., glucose oxidase, glucose dehydrogenase, etc.) or lactateresponsive enzyme (e.g., lactate oxidase). The sensing layer may alsoinclude other optional components, such as, for example, a polymer and abi-functional, short-chain, epoxide cross-linker, such as polyethyleneglycol (PEG).

Any suitable proportion of high-boiling point solvent may be used with asensing layer, where the specifics will depend on, e.g., the particularsensing layer, etc. In certain embodiments, the high-boiling pointsolvent may comprise from 0.5% to 60% (w/v) of the total biosensorsensing layer formulation. For example, such high-boiling point solventsmay comprise from 0.5% to 40% (w/v) of the total biosensor sensing layerformulation, including, for example, from 0.5% to 30% (w/v), from 0.5%to 20% (w/v), from 1% to 15% (w/v), from 1% to 10% (w/v), from 1% to 5%(w/v), and the like. In some cases, the sensing layer formulationincludes 1% (w/v) or more ethylene glycol, such as 3% (w/v) or more, 5%(w/v) or more, 10% (w/v) or more, 15% (w/v) or more, 20% (w/v) or more,25% (w/v) or more, or 30% (w/v) or more ethylene glycol. In certaininstances, the sensing layer formulation includes 1% (w/v) or morediethylene glycol monomethyl ether, such as 3% (w/v) or more, 5% (w/v)or more, 10% (w/v) or more, 15% (w/v) or more, 20% (w/v) or more, 25%(w/v) or more, or 30% (w/v) or more diethylene glycol monomethyl ether.In some embodiments, the sensing layer formulation includes 1% (w/v) ormore diethylene glycol dimethyl ether, such as 3% (w/v) or more, 5%(w/v) or more, 10% (w/v) or more, 15% (w/v) or more, 20% (w/v) or more,25% (w/v) or more, or 30% (w/v) or more diethylene glycol dimethylether. In certain cases, the sensing layer formulation includes 1% (w/v)or more dimethyl sulfoxide, such as 3% (w/v) or more, 5% (w/v) or more,10% (w/v) or more, 15% (w/v) or more, 20% (w/v) or more, 25% (w/v) ormore, or 30% (w/v) or more dimethyl sulfoxide.

In an electrochemical embodiment, the sensor is placed,transcutaneously, for example, into a subcutaneous site such thatsubcutaneous fluid of the site comes into contact with the sensor. Inother in vivo embodiments, placement of at least a portion of the sensormay be in a blood vessel. The sensor operates to electrolyze an analyteof interest in the subcutaneous fluid such that a current is generatedbetween the working electrode and the counter electrode. A value for thecurrent associated with the working electrode is determined. If multipleworking electrodes are used, current values from each of the workingelectrodes may be determined. A microprocessor may be used to collectthese periodically determined current values or to further process thesevalues.

If an analyte concentration is successfully determined, it may bedisplayed, stored, and/or otherwise processed to provide usefulinformation. By way of example, raw signal or analyte concentrations maybe used as a basis for determining a rate of change in analyteconcentration, which should not change at a rate greater than apredetermined threshold amount. If the rate of change of analyteconcentration exceeds the predefined threshold, an indication maybedisplayed or otherwise transmitted to indicate this fact.

As demonstrated herein, the methods of the present disclosure are usefulin connection with a device that is used to measure or monitor a glucoseanalyte, such as any such device described herein. These methods mayalso be used in connection with a device that is used to measure ormonitor another analyte, including oxygen, carbon dioxide, proteins,drugs, or another moiety of interest, for example, or any combinationthereof, found in bodily fluid, including subcutaneous fluid, dermalfluid (sweat, tears, and the like), interstitial fluid, or other bodilyfluid of interest, for example, or any combination thereof. In general,the device is in good contact, such as thorough and substantiallycontinuous contact, with the bodily fluid.

According to embodiments of the present disclosure, the measurementsensor is one suited for electrochemical measurement of analyteconcentration, such as, for example, glucose concentration, in a bodilyfluid. In this embodiment, the measurement sensor comprises at least aworking electrode and a counter electrode. Other embodiments may furthercomprise a reference electrode. The working electrode is typicallyassociated with a glucose-responsive enzyme. A mediator may also beincluded. In certain embodiments, hydrogen peroxide, which may becharacterized as a mediator, is produced by a reaction of the sensor andmay be used to infer the concentration of glucose. In some embodiments,a mediator is added to the sensor by a manufacturer, i.e., is includedwith the sensor even prior to use. Generally, a redox mediator isrelative to the working electrode and is capable of transferringelectrons between a compound and a working electrode, either directly orindirectly. Merely by way of example, the redox mediator may be, and is,for example, immobilized on the working electrode, e.g., entrapped on asurface or chemically bound to a surface.

Electrochemical Sensors

Embodiments of the present disclosure relate to methods and devices fordetecting at least one analyte, including glucose, in body fluid.Embodiments relate to the continuous and/or automatic in vivo monitoringof the level of one or more analytes using a continuous analytemonitoring system that includes an analyte sensor at least a portion ofwhich is to be positioned beneath a skin surface of a user for a periodof time and/or the discrete monitoring of one or more analytes using anin vitro blood glucose (“BG”) meter and an analyte test strip.Embodiments include combined or combinable devices, systems and methodsand/or transferring data between an in vivo continuous system and an invivo system. In some embodiments, the systems, or at least a portion ofthe systems, are integrated into a single unit.

A sensor that includes a high-boiling point solvent may be an in vivosensor or an in vitro sensor (i.e., a discrete monitoring test strip).Such a sensor can be formed on a substrate, e.g., a substantially planarsubstrate. In certain embodiments, such a sensor is a wire, e.g., aworking electrode wire inner portion with one or more other electrodesassociated (e.g., on, including wrapped around) therewith. The sensormay also include at least one counter electrode (or counter/referenceelectrode) and/or at least one reference electrode or at least onereference/counter electrode.

Accordingly, embodiments include analyte monitoring devices and systemsthat include an analyte sensor at least a portion of which ispositionable beneath the skin surface of the user for the in vivodetection of an analyte, including glucose, lactate, and the like, in abody fluid. Embodiments include wholly implantable analyte sensors andanalyte sensors in which only a portion of the sensor is positionedunder the skin and a portion of the sensor resides above the skin, e.g.,for contact to a sensor control unit (which may include a transmitter),a receiver/display unit, transceiver, processor, etc. The sensor may be,for example, subcutaneously positionable in a user for the continuous orperiodic monitoring of a level of an analyte in the user's interstitialfluid. For the purposes of this description, continuous monitoring andperiodic monitoring will be used interchangeably, unless notedotherwise. The sensor response may be correlated and/or converted toanalyte levels in blood or other fluids. In certain embodiments, ananalyte sensor may be positioned in contact with interstitial fluid todetect the level of glucose, which detected glucose may be used to inferthe glucose level in the user's bloodstream. Analyte sensors may beinsertable into a vein, artery, or other portion of the body containingfluid. Embodiments of the analyte sensors having a high-boiling pointsolvent may be configured for monitoring the level of the analyte over atime period which may range from seconds, minutes, hours, days, weeks,to months, or longer.

In certain embodiments, the analyte sensors, such as glucose sensors,have a high-boiling point solvent and are capable of in vivo detectionof an analyte for about one hour or more, e.g., about a few hours ormore, e.g., about a few days or more, e.g., about three or more days,e.g., about five days or more, e.g., about seven days or more, e.g.,about several weeks or at least one month or more. Future analyte levelsmay be predicted based on information obtained, e.g., the currentanalyte level at time t₀, the rate of change of the analyte, etc.Predictive alarms may notify the user of a predicted analyte levels thatmay be of concern in advance of the user's analyte level reaching thefuture level. This provides the user an opportunity to take correctiveaction.

FIG. 1 shows a data monitoring and management system such as, forexample, an analyte (e.g., glucose) monitoring system 100 in accordancewith certain embodiments. Embodiments of the subject disclosure arefurther described primarily with respect to glucose monitoring devicesand systems, and methods of glucose detection, for convenience only andsuch description is in no way intended to limit the scope of theembodiments. It is to be understood that the analyte monitoring systemmay be configured to monitor a variety of analytes at the same time orat different times.

Analytes that may be monitored include, but are not limited to, acetylcholine, amylase, bilirubin, cholesterol, chorionic gonadotropin,creatine kinase (e.g., CK-MB), creatine, creatinine, DNA, fructosamine,glucose, glutamine, growth hormones, hormones, ketone bodies, lactate,peroxide, prostate-specific antigen, prothrombin, RNA, thyroidstimulating hormone, and troponin. The concentration of drugs, such as,for example, antibiotics (e.g., gentamicin, vancomycin, and the like),digitoxin, digoxin, drugs of abuse, theophylline, and warfarin, may alsobe monitored. In embodiments that monitor more than one analyte, theanalytes may be monitored at the same or different times.

The analyte monitoring system 100 includes an analyte sensor 101, a dataprocessing unit 102 connectable to the sensor 101, and a primaryreceiver unit 104. In some instances, the primary receiver unit 104 isconfigured to communicate with the data processing unit 102 via acommunication link 103. In certain embodiments, the primary receiverunit 104 may be further configured to transmit data to a data processingterminal 105 to evaluate or otherwise process or format data received bythe primary receiver unit 104. The data processing terminal 105 may beconfigured to receive data directly from the data processing unit 102via a communication link 107, which may optionally be configured forbi-directional communication. Further, the data processing unit 102 mayinclude a transmitter or a transceiver to transmit and/or receive datato and/or from the primary receiver unit 104 and/or the data processingterminal 105 and/or optionally a secondary receiver unit 106.

Also shown in FIG. 1 is an optional secondary receiver unit 106 which isoperatively coupled to the communication link 103 and configured toreceive data transmitted from the data processing unit 102. Thesecondary receiver unit 106 may be configured to communicate with theprimary receiver unit 104, as well as the data processing terminal 105.In certain embodiments, the secondary receiver unit 106 may beconfigured for bi-directional wireless communication with each of theprimary receiver unit 104 and the data processing terminal 105. Asdiscussed in further detail below, in some instances, the secondaryreceiver unit 106 may be a de-featured receiver as compared to theprimary receiver unit 104, i.e., the secondary receiver unit 106 mayinclude a limited or minimal number of functions and features ascompared with the primary receiver unit 104. As such, the secondaryreceiver unit 106 may include a smaller (in one or more, including all,dimensions), compact housing or embodied in a device including a wristwatch, arm band, PDA, mp3 player, cell phone, etc., for example.Alternatively, the secondary receiver unit 106 may be configured withthe same or substantially similar functions and features as the primaryreceiver unit 104. The secondary receiver unit 106 may include a dockingportion configured to mate with a docking cradle unit for placement by,e.g., the bedside for night time monitoring, and/or a bi-directionalcommunication device. A docking cradle may recharge a power supply.

Only one analyte sensor 101, data processing unit 102 and dataprocessing terminal 105 are shown in the embodiment of the analytemonitoring system 100 illustrated in FIG. 1. However, it will beappreciated by one of ordinary skill in the art that the analytemonitoring system 100 may include more than one sensor 101 and/or morethan one data processing unit 102, and/or more than one data processingterminal 105. Multiple sensors may be positioned in a user for analytemonitoring at the same or different times. In certain embodiments,analyte information obtained by a first sensor positioned in a user maybe employed as a comparison to analyte information obtained by a secondsensor. This may be useful to confirm or validate analyte informationobtained from one or both of the sensors. Such redundancy may be usefulif analyte information is contemplated in critical therapy-relateddecisions. In certain embodiments, a first sensor may be used tocalibrate a second sensor.

The analyte monitoring system 100 may be a continuous monitoring system,or semi-continuous, or a discrete monitoring system. In amulti-component environment, each component may be configured to beuniquely identified by one or more of the other components in the systemso that communication conflict may be readily resolved between thevarious components within the analyte monitoring system 100. Forexample, unique IDs, communication channels, and the like, may be used.

In certain embodiments, the sensor 101 is physically positioned in or onthe body of a user whose analyte level is being monitored. The sensor101 may be configured to at least periodically sample the analyte levelof the user and convert the sampled analyte level into a correspondingsignal for transmission by the data processing unit 102. The dataprocessing unit 102 is coupleable to the sensor 101 so that both devicesare positioned in or on the user's body, with at least a portion of theanalyte sensor 101 positioned transcutaneously. The data processing unitmay include a fixation element such as an adhesive or the like to secureit to the user's body. A mount (not shown) attachable to the user andmateable with the data processing unit 102 may be used. For example, amount may include an adhesive surface. The data processing unit 102performs data processing functions, where such functions may include butare not limited to, filtering and encoding of data signals, each ofwhich corresponds to a sampled analyte level of the user, fortransmission to the primary receiver unit 104 via the communication link103. In one embodiment, the sensor 101 or the data processing unit 102or a combined sensor/data processing unit may be wholly implantableunder the skin surface of the user.

In certain embodiments, the primary receiver unit 104 may include ananalog interface section including an RF receiver and an antenna that isconfigured to communicate with the data processing unit 102 via thecommunication link 103, and a data processing section for processing thereceived data from the data processing unit 102 including data decoding,error detection and correction, data clock generation, data bitrecovery, etc., or any combination thereof.

In operation, the primary receiver unit 104 in certain embodiments isconfigured to synchronize with the data processing unit 102 to uniquelyidentify the data processing unit 102, based on, for example, anidentification information of the data processing unit 102, andthereafter, to periodically receive signals transmitted from the dataprocessing unit 102 associated with the monitored analyte levelsdetected by the sensor 101.

Referring again to FIG. 1, the data processing terminal 105 may includea personal computer, a portable computer including a laptop or ahandheld device (e.g., a personal digital assistant (PDAs), a telephoneincluding a cellular phone (e.g., a multimedia and Internet-enabledmobile phone including an iPhone™, a Blackberry®, or similar phone), anmp3 player (e.g., an iPOD™, etc.), a pager, and the like), and/or a drugdelivery device (e.g., an infusion device), each of which may beconfigured for data communication with the receiver via a wired or awireless connection. Additionally, the data processing terminal 105 mayfurther be connected to a data network (not shown) for storing,retrieving, updating, and/or analyzing data corresponding to thedetected analyte level of the user.

The data processing terminal 105 may include an infusion device such asan insulin infusion pump or the like, which may be configured toadminister insulin to the user, and which may be configured tocommunicate with the primary receiver unit 104 for receiving, amongothers, the measured analyte level. Alternatively, the primary receiverunit 104 may be configured to integrate an infusion device therein sothat the primary receiver unit 104 is configured to administer anappropriate drug (e.g., insulin) to users, for example, foradministering and modifying basal profiles, as well as for determiningappropriate boluses for administration based on, among others, thedetected analyte levels received from the data processing unit 102. Aninfusion device may be an external device or an internal device (whollyimplantable in a user).

In certain embodiments, the data processing terminal 105, which mayinclude an infusion device, e.g., an insulin pump, may be configured toreceive the analyte signals from the data processing unit 102, and thus,incorporate the functions of the primary receiver unit 104 includingdata processing for managing the user's insulin therapy and analytemonitoring. In certain embodiments, the communication link 103, as wellas one or more of the other communication interfaces shown in FIG. 1,may use one or more of: an RF communication protocol, an infraredcommunication protocol, a Bluetooth enabled communication protocol, an802.11x wireless communication protocol, or an equivalent wirelesscommunication protocol which would allow secure, wireless communicationof several units (for example, per Health Insurance Portability andAccountability Act (HIPPA) requirements), while avoiding potential datacollision and interference.

FIG. 2 shows a block diagram of an embodiment of a data processing unit102 of the analyte monitoring system shown in FIG. 1. User input and/orinterface components may be included or a data processing unit may befree of user input and/or interface components. In certain embodiments,one or more application-specific integrated circuits (ASIC) may be usedto implement one or more functions or routines associated with theoperations of the data processing unit (and/or receiver unit) using forexample one or more state machines and buffers.

As can be seen in the embodiment of FIG. 2, the analyte sensor 101(FIG. 1) includes four contacts, three of which are electrodes: a workelectrode (W) 210, a reference electrode (R) 212, and a counterelectrode (C) 213, each operatively coupled to the analog interface 201of the data processing unit 102. This embodiment also shows an optionalguard contact (G) 211. Fewer or greater electrodes may be employed. Forexample, the counter and reference electrode functions may be served bya single counter/reference electrode. In some cases, there may be morethan one working electrode and/or reference electrode and/or counterelectrode, etc.

FIG. 3 is a block diagram of an embodiment of a receiver/monitor unitsuch as the primary receiver unit 104 of the analyte monitoring systemshown in FIG. 1. The primary receiver unit 104 includes one or more of:a test strip interface 301, an RF receiver 302, a user input 303, atemperature detection section 304, and a clock 305, each of which isoperatively coupled to a processing and storage section 307. The primaryreceiver unit 104 also includes a power supply 306 operatively coupledto a power conversion and monitoring section 308. Further, the powerconversion and monitoring section 308 is also coupled to the processingand storage section 307. Moreover, also shown are a receiver serialcommunication section 309, and an output 310, each operatively coupledto the processing and storage section 307. The primary receiver unit 104may include user input and/or interface components or may be free ofuser input and/or interface components.

In certain embodiments, the test strip interface 301 includes a glucoselevel testing portion to receive a blood (or other body fluid sample)glucose test or information related thereto. For example, the test stripinterface 301 may include a test strip port to receive a glucose teststrip. The device may determine the glucose level of the test strip, andoptionally display (or otherwise notice) the glucose level on the output310 of the primary receiver unit 104. Any suitable test strip may beemployed, e.g., test strips that only require a very small amount (e.g.,3 microliters or less, e.g., 1 microliter or less, e.g., 0.5 microlitersor less, e.g., 0.1 microliters or less), of applied sample to the stripin order to obtain accurate glucose information. Embodiments of teststrips include, e.g., FreeStyle® blood glucose test strips from AbbottDiabetes Care, Inc (Alameda, Calif.). Glucose information obtained bythe in vitro glucose testing device may be used for a variety ofpurposes, computations, etc. For example, the information may be used tocalibrate sensor 101, confirm results of sensor 101 to increase theconfidence thereof (e.g., in instances in which information obtained bysensor 101 is employed in therapy related decisions), etc.

In further embodiments, the data processing unit 102 and/or the primaryreceiver unit 104 and/or the secondary receiver unit 106, and/or thedata processing terminal/infusion device 105 may be configured toreceive the blood glucose value wirelessly over a communication linkfrom, for example, a blood glucose meter. In further embodiments, a usermanipulating or using the analyte monitoring system 100 (FIG. 1) maymanually input the blood glucose value using, for example, a userinterface (for example, a keyboard, keypad, voice commands, and thelike) incorporated in one or more of the data processing unit 102, theprimary receiver unit 104, secondary receiver unit 106, or the dataprocessing terminal/infusion device 105.

Additional detailed descriptions are provided in U.S. Pat. Nos.5,262,035; 5,264,104; 5,262,305; 5,320,715; 5,593,852; 6,175,752;6,650,471; 6,746,582, and in application Ser. No. 10/745,878 filed Dec.26, 2003 entitled “Continuous Glucose Monitoring System and Methods ofUse”, each of which is incorporated herein by reference in theirentirety.

FIG. 4 schematically shows an embodiment of an analyte sensor 400 inaccordance with the embodiments of the present disclosure. This sensorembodiment includes electrodes 401, 402 and 403 on a base 404.Electrodes (and/or other features) may be applied or otherwise processedusing any suitable technology, e.g., chemical vapor deposition (CVD),physical vapor deposition, sputtering, reactive sputtering, printing,coating, ablating (e.g., laser ablation), painting, dip coating,etching, and the like. Materials include, but are not limited to, anyone or more of aluminum, carbon (including graphite), cobalt, copper,gallium, gold, indium, iridium, iron, lead, magnesium, mercury (as anamalgam), nickel, niobium, osmium, palladium, platinum, rhenium,rhodium, selenium, silicon (e.g., doped polycrystalline silicon),silver, tantalum, tin, titanium, tungsten, uranium, vanadium, zinc,zirconium, mixtures thereof, and alloys, oxides, or metallic compoundsof these elements.

The analyte sensor 400 may be wholly implantable in a user or may beconfigured so that only a portion is positioned within (internal) a userand another portion outside (external) a user. For example, the sensor400 may include a first portion positionable above a surface of the skin410, and a second portion positioned below the surface of the skin. Insuch embodiments, the external portion may include contacts (connectedto respective electrodes of the second portion by traces) to connect toanother device also external to the user such as a transmitter unit.While the embodiment of FIG. 4 shows three electrodes side-by-side onthe same surface of base 404, other configurations are contemplated,e.g., fewer or greater electrodes, some or all electrodes on differentsurfaces of the base or present on another base, some or all electrodesstacked together, electrodes of differing materials and dimensions, etc.

FIG. 5A shows a perspective view of an embodiment of an analyte sensor500 having a first portion (which in this embodiment may becharacterized as a major portion) positionable above a surface of theskin 510, and a second portion (which in this embodiment may becharacterized as a minor portion) that includes an insertion tip 530positionable below the surface of the skin, e.g., penetrating throughthe skin and into, e.g., the subcutaneous space 520, in contact with theuser's biofluid such as interstitial fluid. Contact portions of aworking electrode 511, a reference electrode 512, and a counterelectrode 513 are positioned on the first portion of the sensor 500situated above the skin surface 510. A working electrode 501, areference electrode 502, and a counter electrode 503 are shown at thesecond portion of the sensor 500 and particularly at the insertion tip530. Traces may be provided from the electrodes at the tip to thecontact, as shown in FIG. 5A. It is to be understood that greater orfewer electrodes may be provided on a sensor. For example, a sensor mayinclude more than one working electrode and/or the counter and referenceelectrodes may be a single counter/reference electrode, etc.

FIG. 5B shows a cross sectional view of a portion of the sensor 500 ofFIG. 5A. The electrodes 501, 502 and 503, of the sensor 500 as well asthe substrate and the dielectric layers are provided in a layeredconfiguration or construction. For example, as shown in FIG. 5B, in oneembodiment, the sensor 500 (such as the analyte sensor 101 of FIG. 1),includes a substrate layer 504, and a first conducting layer 501 such ascarbon, gold, etc., disposed on at least a portion of the substratelayer 504, and which may provide the working electrode. Also showndisposed on at least a portion of the first conducting layer 501 is asensing layer 508.

A first insulation layer 505, such as a first dielectric layer incertain embodiments, is disposed or layered on at least a portion of thefirst conducting layer 501, and further, a second conducting layer 509may be disposed or stacked on top of at least a portion of the firstinsulation layer (or dielectric layer) 505. As shown in FIG. 5B, thesecond conducting layer 509 may provide the reference electrode 502, asdescribed herein having an extended lifetime, which includes a layer ofredox polymer as described herein.

A second insulation layer 506, such as a second dielectric layer incertain embodiments, may be disposed or layered on at least a portion ofthe second conducting layer 509. Further, a third conducting layer 503may be disposed on at least a portion of the second insulation layer 506and may provide the counter electrode 503. Finally, a third insulationlayer 507 may be disposed or layered on at least a portion of the thirdconducting layer 503. In this manner, the sensor 500 may be layered suchthat at least a portion of each of the conducting layers is separated bya respective insulation layer (for example, a dielectric layer). Theembodiments of FIGS. 5A and 5B show the layers having different lengths.In certain instances, some or all of the layers may have the same ordifferent lengths and/or widths.

In certain embodiments, some or all of the electrodes 501, 502, 503 maybe provided on the same side of the substrate 504 in the layeredconstruction as described above, or alternatively, may be provided in aco-planar manner such that two or more electrodes may be positioned onthe same plane (e.g., side-by side (e.g., parallel) or angled relativeto each other) on the substrate 504. For example, co-planar electrodesmay include a suitable spacing therebetween and/or include a dielectricmaterial or insulation material disposed between the conductinglayers/electrodes. Furthermore, in certain embodiments one or more ofthe electrodes 501, 502, 503 may be disposed on opposing sides of thesubstrate 504. In such embodiments, contact pads may be one the same ordifferent sides of the substrate. For example, an electrode may be on afirst side and its respective contact may be on a second side, e.g., atrace connecting the electrode and the contact may traverse through thesubstrate.

As noted above, analyte sensors may include an analyte-responsive enzymeto provide a sensing component or sensing layer. Some analytes, such asoxygen, can be directly electrooxidized or electroreduced on a sensor,and more specifically at least on a working electrode of a sensor. Otheranalytes, such as glucose and lactate, require the presence of at leastone electron transfer agent and/or at least one catalyst to facilitatethe electrooxidation or electroreduction of the analyte. Catalysts mayalso be used for those analytes, such as oxygen, that can be directlyelectrooxidized or electroreduced on the working electrode. For theseanalytes, each working electrode includes a sensing layer (see forexample sensing layer 508 of FIG. 5B) proximate to or on a surface of aworking electrode. In many embodiments, a sensing layer is formed nearor on only a small portion of at least a working electrode.

The sensing layer includes one or more components constructed tofacilitate the electrochemical oxidation or reduction of the analyte.The sensing layer may include, for example, a catalyst to catalyze areaction of the analyte and produce a response at the working electrode,an electron transfer agent to transfer electrons between the analyte andthe working electrode (or other component), or both.

A variety of different sensing layer configurations may be used. Incertain embodiments, the sensing layer is deposited on the conductivematerial of a working electrode. The sensing layer may extend beyond theconductive material of the working electrode. In some cases, the sensinglayer may also extend over other electrodes, e.g., over the counterelectrode and/or reference electrode (or counter/reference is provided).

A sensing layer that is in direct contact with the working electrode maycontain an electron transfer agent to transfer electrons directly orindirectly between the analyte and the working electrode, and/or acatalyst to facilitate a reaction of the analyte. For example, aglucose, lactate, or oxygen electrode may be formed having a sensinglayer which contains a catalyst, including glucose oxidase, glucosedehydrogenase, lactate oxidase, or laccase, respectively, and anelectron transfer agent that facilitates the electrooxidation of theglucose, lactate, or oxygen, respectively.

In other embodiments the sensing layer is not deposited directly on theworking electrode. Instead, the sensing layer 508 may be spaced apartfrom the working electrode, and separated from the working electrode,e.g., by a separation layer. A separation layer may include one or moremembranes or films or a physical distance. In addition to separating theworking electrode from the sensing layer, the separation layer may alsoact as a mass transport limiting layer and/or an interferent eliminatinglayer and/or a biocompatible layer.

In certain embodiments which include more than one working electrode,one or more of the working electrodes may not have a correspondingsensing layer, or may have a sensing layer which does not contain one ormore components (e.g., an electron transfer agent and/or catalyst)needed to electrolyze the analyte. Thus, the signal at this workingelectrode may correspond to background signal which may be removed fromthe analyte signal obtained from one or more other working electrodesthat are associated with fully-functional sensing layers by, forexample, subtracting the signal.

In certain embodiments, the sensing layer includes one or more electrontransfer agents. Electron transfer agents that may be employed areelectroreducible and electrooxidizable ions or molecules having redoxpotentials that are a few hundred millivolts above or below the redoxpotential of the standard calomel electrode (SCE). The electron transferagent may be organic, organometallic, or inorganic. Examples of organicredox species are quinones and species that in their oxidized state havequinoid structures, such as Nile blue and indophenol. Examples oforganometallic redox species are metallocenes including ferrocene.Examples of inorganic redox species are hexacyanoferrate (III),ruthenium hexamine, etc. Additional examples include those described inU.S. Pat. Nos. 7,501,053 and 6,736,957 and U.S. Patent Publication No.2006/0201805, the disclosures of which are incorporated herein byreference in their entirety.

In certain embodiments, electron transfer agents have structures orcharges which prevent or substantially reduce the diffusional loss ofthe electron transfer agent during the period of time that the sample isbeing analyzed. For example, electron transfer agents include but arenot limited to a redox species, e.g., bound to a polymer which can inturn be disposed on or near the working electrode. The bond between theredox species and the polymer may be covalent, coordinative, or ionic.Although any organic, organometallic or inorganic redox species may bebound to a polymer and used as an electron transfer agent, in certainembodiments the redox species is a transition metal compound or complex,e.g., osmium, ruthenium, iron, and cobalt compounds or complexes. Itwill be recognized that many redox species described for use with apolymeric component may also be used, without a polymeric component.

One type of polymeric electron transfer agent contains a redox speciescovalently bound in a polymeric composition. An example of this type ofmediator is poly(vinylferrocene). Another type of electron transferagent contains an ionically-bound redox species. This type of mediatormay include a charged polymer coupled to an oppositely charged redoxspecies. Examples of this type of mediator include a negatively chargedpolymer coupled to a positively charged redox species such as an osmiumor ruthenium polypyridyl cation. Another example of an ionically-boundmediator is a positively charged polymer including quaternizedpoly(4-vinyl pyridine) or poly(1-vinyl imidazole) coupled to anegatively charged redox species such as ferricyanide or ferrocyanide.In other embodiments, electron transfer agents include a redox speciescoordinatively bound to a polymer. For example, the mediator may beformed by coordination of an osmium or cobalt 2,2′-bipyridyl complex topoly(1-vinyl imidazole) or poly(4-vinyl pyridine).

Suitable electron transfer agents are osmium transition metal complexeswith one or more ligands, each ligand having a nitrogen-containingheterocycle such as 2,2′-bipyridine, 1,10-phenanthroline, 1-methyl,2-pyridyl biimidazole, or derivatives thereof. The electron transferagents may also have one or more ligands covalently bound in a polymer,each ligand having at least one nitrogen-containing heterocycle, such aspyridine, imidazole, or derivatives thereof. One example of an electrontransfer agent includes (a) a polymer or copolymer having pyridine orimidazole functional groups and (b) osmium cations complexed with twoligands, each ligand containing 2,2′-bipyridine, 1,10-phenanthroline, orderivatives thereof, the two ligands not necessarily being the same.Some derivatives of 2,2′-bipyridine for complexation with the osmiumcation include but are not limited to 4,4′-dimethyl-2,2′-bipyridine andmono-, di-, and polyalkoxy-2,2′-bipyridines, including4,4′-dimethoxy-2,2′-bipyridine. Derivatives of 1,10-phenanthroline forcomplexation with the osmium cation include but are not limited to4,7-dimethyl-1,10-phenanthroline and mono, di-, andpolyalkoxy-1,10-phenanthrolines, such as4,7-dimethoxy-1,10-phenanthroline. Polymers for complexation with theosmium cation include but are not limited to polymers and copolymers ofpoly(1-vinyl imidazole) (referred to as “PVI”) and poly(4-vinylpyridine) (referred to as “PVP”). Suitable copolymer substituents ofpoly(1-vinyl imidazole) include acrylonitrile, acrylamide, andsubstituted or quaternized N-vinyl imidazole, e.g., electron transferagents with osmium complexed to a polymer or copolymer of poly(1-vinylimidazole).

Embodiments may employ electron transfer agents having a redox potentialranging from about −200 mV to about +200 mV versus the standard calomelelectrode (SCE). The sensing layer may also include a catalyst which iscapable of catalyzing a reaction of the analyte. The catalyst may also,in some embodiments, act as an electron transfer agent. One example of asuitable catalyst is an enzyme which catalyzes a reaction of theanalyte. For example, a catalyst, including a glucose oxidase, glucosedehydrogenase (e.g., pyrroloquinoline quinone (PQQ), dependent glucosedehydrogenase, flavine adenine dinucleotide (FAD) dependent glucosedehydrogenase, or nicotinamide adenine dinucleotide (NAD) dependentglucose dehydrogenase), may be used when the analyte of interest isglucose. A lactate oxidase or lactate dehydrogenase may be used when theanalyte of interest is lactate. Laccase may be used when the analyte ofinterest is oxygen or when oxygen is generated or consumed in responseto a reaction of the analyte.

The sensing layer may also include a catalyst which is capable ofcatalyzing a reaction of the analyte. The catalyst may also, in someembodiments, act as an electron transfer agent. One example of asuitable catalyst is an enzyme which catalyzes a reaction of theanalyte. For example, a catalyst, including a glucose oxidase, glucosedehydrogenase (e.g., pyrroloquinoline quinone (PQQ) dependent glucosedehydrogenase or oligosaccharide dehydrogenase, flavine adeninedinucleotide (FAD) dependent glucose dehydrogenase, nicotinamide adeninedinucleotide (NAD) dependent glucose dehydrogenase), may be used whenthe analyte of interest is glucose. A lactate oxidase or lactatedehydrogenase may be used when the analyte of interest is lactate.Laccase may be used when the analyte of interest is oxygen or whenoxygen is generated or consumed in response to a reaction of theanalyte.

In certain embodiments, a catalyst may be attached to a polymer, crosslinking the catalyst with another electron transfer agent, which, asdescribed above, may be polymeric. A second catalyst may also be used incertain embodiments. This second catalyst may be used to catalyze areaction of a product compound resulting from the catalyzed reaction ofthe analyte. The second catalyst may operate with an electron transferagent to electrolyze the product compound to generate a signal at theworking electrode. Alternatively, a second catalyst may be provided inan interferent-eliminating layer to catalyze reactions that removeinterferents.

In certain embodiments, the sensor includes a high-boiling point solventand works at a gentle oxidizing potential, e.g., a potential of about+40 mV vs. Ag/AgCl. This sensing layer uses, for example, an osmium(Os)-based mediator constructed for low potential operation and includesa high-boiling point solvent. Accordingly, in certain embodiments thesensing element is a redox active component that includes (1)Osmium-based mediator molecules that include (bidente) ligands, and (2)glucose oxidase enzyme molecules. These two constituents are combinedtogether with a high-boiling point solvent.

A mass transport limiting layer (not shown), e.g., an analyte fluxmodulating layer, may be included with the sensor to act as adiffusion-limiting barrier to reduce the rate of mass transport of theanalyte, for example, glucose or lactate, into the region around theworking electrodes. The mass transport limiting layers are useful inlimiting the flux of an analyte to a working electrode in anelectrochemical sensor so that the sensor is linearly responsive over alarge range of analyte concentrations and is easily calibrated. Masstransport limiting layers may include polymers and may be biocompatible.A mass transport limiting layer may provide many functions, e.g.,biocompatibility and/or interferent-eliminating, etc.

In certain embodiments, a mass transport limiting layer is a membranecomposed of crosslinked polymers containing heterocyclic nitrogengroups, such as polymers of polyvinylpyridine and polyvinylimidazole.Embodiments also include membranes that are made of a polyurethane, orpolyether urethane, or chemically related material, or membranes thatare made of silicone, and the like.

A membrane may be formed by crosslinking in situ a polymer, modifiedwith a zwitterionic moiety, a non-pyridine copolymer component, andoptionally another moiety that is either hydrophilic or hydrophobic,and/or has other desirable properties, in an alcohol-buffer solution.The modified polymer may be made from a precursor polymer containingheterocyclic nitrogen groups. For example, a precursor polymer may bepolyvinylpyridine or polyvinylimidazole. Optionally, hydrophilic orhydrophobic modifiers may be used to “fine-tune” the permeability of theresulting membrane to an analyte of interest. Optional hydrophilicmodifiers, such as poly(ethylene glycol), hydroxyl or polyhydroxylmodifiers, may be used to enhance the biocompatibility of the polymer orthe resulting membrane.

A membrane may be formed in situ by applying an alcohol-buffer solutionof a crosslinker and a modified polymer over an enzyme-containingsensing layer and allowing the solution to cure for about one to twodays or other appropriate time period. The crosslinker-polymer solutionmay be applied to the sensing layer by placing a droplet or droplets ofthe solution on the sensor, by dipping the sensor into the solution, byspraying the solution on the sensor, and the like. Generally, thethickness of the membrane is controlled by the concentration of thesolution, by the number of droplets of the solution applied, by thenumber of times the sensor is dipped in the solution, by the volume ofsolution sprayed on the sensor, or by any combination of these factors.A membrane applied in this manner may have any combination of thefollowing functions: (1) mass transport limitation, i.e., reduction ofthe flux of analyte that can reach the sensing layer, (2)biocompatibility enhancement, or (3) interferent reduction.

In some instances, the membrane may form one or more bonds with thesensing layer. By bonds is meant any type of an interaction betweenatoms or molecules that allows chemical compounds to form associationswith each other, such as, but not limited to, covalent bonds, ionicbonds, dipole-dipole interactions, hydrogen bonds, London dispersionforces, and the like. For example, in situ polymerization of themembrane can form crosslinks between the polymers of the membrane andthe polymers in the sensing layer. In certain embodiments, crosslinkingof the membrane to the sensing layer facilitates a reduction in theoccurrence of delamination of the membrane from the sensing layer.

In certain embodiments, the sensing system detects hydrogen peroxide toinfer glucose levels. For example, a hydrogen peroxide-detecting sensormay be constructed in which a sensing layer includes enzyme such asglucose oxides, glucose dehydrogenase, or the like, and is positionedproximate to the working electrode. The sensing layer may be covered byone or more layers, e.g., a membrane that is selectively permeable toglucose. Once the glucose passes through the membrane, it is oxidized bythe enzyme and reduced glucose oxidase can then be oxidized by reactingwith molecular oxygen to produce hydrogen peroxide.

Certain embodiments include a hydrogen peroxide-detecting sensorconstructed from a sensing layer prepared by combining together, forexample: (1) a redox mediator having a transition metal complexincluding an Os polypyridyl complex with oxidation potentials of about+200 mV vs. SCE, (2) a high-boiling point solvent, and (3) periodateoxidized horseradish peroxidase (HRP). Such a sensor functions in areductive mode; the working electrode is controlled at a potentialnegative to that of the Os complex, resulting in mediated reduction ofhydrogen peroxide through the HRP catalyst.

In another example, a potentiometric sensor can be constructed asfollows. A glucose-sensing layer is constructed by combining together(1) a redox mediator having a transition metal complex including an Ospolypyridyl complexes with oxidation potentials from about −200 mV to+200 mV vs. SCE, and (2) a high-boiling point solvent, and (3) glucoseoxidase. This sensor can then be used in a potentiometric mode, byexposing the sensor to a glucose containing solution, under conditionsof zero current flow, and allowing the ratio of reduced/oxidized Os toreach an equilibrium value. The reduced/oxidized Os ratio varies in areproducible way with the glucose concentration, and will cause theelectrode's potential to vary in a similar way.

The substrate may be formed using a variety of non-conducting materials,including, for example, polymeric or plastic materials and ceramicmaterials. Suitable materials for a particular sensor may be determined,at least in part, based on the desired use of the sensor and propertiesof the materials.

In some embodiments, the substrate is flexible. For example, if thesensor is configured for implantation into a user, then the sensor maybe made flexible (although rigid sensors may also be used forimplantable sensors) to reduce pain to the user and damage to the tissuecaused by the implantation of and/or the wearing of the sensor. Aflexible substrate often increases the user's comfort and allows a widerrange of activities. Suitable materials for a flexible substrateinclude, for example, non-conducting plastic or polymeric materials andother non-conducting, flexible, deformable materials. Examples of usefulplastic or polymeric materials include thermoplastics such aspolycarbonates, polyesters (e.g., Mylar™ and polyethylene terephthalate(PET)), polyvinyl chloride (PVC), polyurethanes, polyethers, polyamides,polyimides, or copolymers of these thermoplastics, such as PETG(glycol-modified polyethylene terephthalate).

In other embodiments, the sensors are made using a relatively rigidsubstrate to, for example, provide structural support against bending orbreaking. Examples of rigid materials that may be used as the substrateinclude poorly conducting ceramics, such as aluminum oxide and silicondioxide. An implantable sensor having a rigid substrate may have a sharppoint and/or a sharp edge to aid in implantation of a sensor without anadditional insertion device.

It will be appreciated that for many sensors and sensor applications,both rigid and flexible sensors will operate adequately. The flexibilityof the sensor may also be controlled and varied along a continuum bychanging, for example, the composition and/or thickness of thesubstrate.

In addition to considerations regarding flexibility, it is oftendesirable that implantable sensors should have a substrate which isphysiologically harmless, for example, a substrate approved by aregulatory agency or private institution for in vivo use.

The sensor may include optional features to facilitate insertion of animplantable sensor. For example, the sensor may be pointed at the tip toease insertion. In addition, the sensor may include a barb which assistsin anchoring the sensor within the tissue of the user during operationof the sensor. However, the barb is typically small enough so thatlittle damage is caused to the subcutaneous tissue when the sensor isremoved for replacement.

An implantable sensor may also, optionally, have an anticlotting agentdisposed on a portion of the substrate which is implanted into a user.This anticlotting agent may reduce or eliminate the clotting of blood orother body fluid around the sensor, particularly after insertion of thesensor. Blood clots may foul the sensor or irreproducibly reduce theamount of analyte which diffuses into the sensor. Examples of usefulanticlotting agents include heparin and tissue plasminogen activator(TPA), as well as other known anticlotting agents.

The anticlotting agent may be applied to at least a portion of that partof the sensor that is to be implanted. The anticlotting agent may beapplied, for example, by bath, spraying, brushing, or dipping, etc. Theanticlotting agent is allowed to dry on the sensor. The anticlottingagent may be immobilized on the surface of the sensor or it may beallowed to diffuse away from the sensor surface. Typically, thequantities of anticlotting agent disposed on the sensor are far belowthe amounts typically used for treatment of medical conditions involvingblood clots and, therefore, have only a limited, localized effect.

Insertion Device

An insertion device can be used to subcutaneously insert the sensor intothe user. The insertion device is typically formed using structurallyrigid materials, such as metal or rigid plastic. Materials may includestainless steel and ABS (acrylonitrile-butadiene-styrene) plastic. Insome embodiments, the insertion device is pointed and/or sharp at thetip to facilitate penetration of the skin of the user. A sharp, thininsertion device may reduce pain felt by the user upon insertion of thesensor. In other embodiments, the tip of the insertion device has othershapes, including a blunt or flat shape. These embodiments may be usefulwhen the insertion device does not penetrate the skin but rather servesas a structural support for the sensor as the sensor is pushed into theskin.

Sensor Control Unit

The sensor control unit can be integrated in the sensor, part or all ofwhich is subcutaneously implanted or it can be configured to be placedon the skin of a user. The sensor control unit is optionally formed in ashape that is comfortable to the user and which may permit concealment,for example, under a user's clothing. The thigh, leg, upper arm,shoulder, or abdomen are convenient parts of the user's body forplacement of the sensor control unit to maintain concealment. However,the sensor control unit may be positioned on other portions of theuser's body. One embodiment of the sensor control unit has a thin, ovalshape to enhance concealment. However, other shapes and sizes may beused.

The particular profile, as well as the height, width, length, weight,and volume of the sensor control unit may vary and depends, at least inpart, on the components and associated functions included in the sensorcontrol unit. In general, the sensor control unit includes a housingtypically formed as a single integral unit that rests on the skin of theuser. The housing typically contains most or all of the electroniccomponents of the sensor control unit.

The housing of the sensor control unit may be formed using a variety ofmaterials, including, for example, plastic and polymeric materials, suchas rigid thermoplastics and engineering thermoplastics. Suitablematerials include, for example, polyvinyl chloride, polyethylene,polypropylene, polystyrene, ABS polymers, and copolymers thereof. Thehousing of the sensor control unit may be formed using a variety oftechniques including, for example, injection molding, compressionmolding, casting, and other molding methods. Hollow or recessed regionsmay be formed in the housing of the sensor control unit. The electroniccomponents of the sensor control unit and/or other items, including abattery or a speaker for an audible alarm, may be placed in the hollowor recessed areas.

The sensor control unit is typically attached to the skin of the user,for example, by adhering the sensor control unit directly to the skin ofthe user with an adhesive provided on at least a portion of the housingof the sensor control unit which contacts the skin or by suturing thesensor control unit to the skin through suture openings in the sensorcontrol unit.

When positioned on the skin of a user, the sensor and the electroniccomponents within the sensor control unit are coupled via conductivecontacts. The one or more working electrodes, counter electrode (orcounter/reference electrode), optional reference electrode, and optionaltemperature probe are attached to individual conductive contacts. Forexample, the conductive contacts are provided on the interior of thesensor control unit. Other embodiments of the sensor control unit havethe conductive contacts disposed on the exterior of the housing. Theplacement of the conductive contacts is such that they are in contactwith the contact pads on the sensor when the sensor is properlypositioned within the sensor control unit.

Sensor Control Unit Electronics

The sensor control unit also typically includes at least a portion ofthe electronic components that operate the sensor and the analytemonitoring device system. The electronic components of the sensorcontrol unit typically include a power supply for operating the sensorcontrol unit and the sensor, a sensor circuit for obtaining signals fromand operating the sensor, a measurement circuit that converts sensorsignals to a desired format, and a processing circuit that, at minimum,obtains signals from the sensor circuit and/or measurement circuit andprovides the signals to an optional transmitter. In some embodiments,the processing circuit may also partially or completely evaluate thesignals from the sensor and convey the resulting data to the optionaltransmitter and/or activate an optional alarm system if the analytelevel exceeds a threshold. The processing circuit often includes digitallogic circuitry.

The sensor control unit may optionally contain a transmitter fortransmitting the sensor signals or processed data from the processingcircuit to a receiver/display unit; a data storage unit for temporarilyor permanently storing data from the processing circuit; a temperatureprobe circuit for receiving signals from and operating a temperatureprobe; a reference voltage generator for providing a reference voltagefor comparison with sensor-generated signals; and/or a watchdog circuitthat monitors the operation of the electronic components in the sensorcontrol unit.

Moreover, the sensor control unit may also include digital and/or analogcomponents utilizing semiconductor devices, including transistors. Tooperate these semiconductor devices, the sensor control unit may includeother components including, for example, a bias control generator tocorrectly bias analog and digital semiconductor devices, an oscillatorto provide a clock signal, and a digital logic and timing component toprovide timing signals and logic operations for the digital componentsof the circuit.

As an example of the operation of these components, the sensor circuitand the optional temperature probe circuit provide raw signals from thesensor to the measurement circuit. The measurement circuit converts theraw signals to a desired format, using for example, a current-to-voltageconverter, current-to-frequency converter, and/or a binary counter orother indicator that produces a signal proportional to the absolutevalue of the raw signal. This may be used, for example, to convert theraw signal to a format that can be used by digital logic circuits. Theprocessing circuit may then, optionally, evaluate the data and providecommands to operate the electronics.

Calibration

Sensors may be configured to require no system calibration or no usercalibration. For example, a sensor may be factory calibrated and neednot require further calibrating. In certain embodiments, calibration maybe required, but may be done without user intervention, i.e., may beautomatic. In those embodiments in which calibration by the user isrequired, the calibration may be according to a predetermined scheduleor may be dynamic, i.e., the time for which may be determined by thesystem on a real-time basis according to various factors, including, butnot limited to, glucose concentration and/or temperature and/or rate ofchange of glucose, etc.

In addition to a transmitter, an optional receiver may be included inthe sensor control unit. In some cases, the transmitter is atransceiver, operating as both a transmitter and a receiver. Thereceiver may be used to receive calibration data for the sensor. Thecalibration data may be used by the processing circuit to correctsignals from the sensor. This calibration data may be transmitted by thereceiver/display unit or from some other source such as a control unitin a doctor's office. In addition, the optional receiver may be used toreceive a signal from the receiver/display units to direct thetransmitter, for example, to change frequencies or frequency bands, toactivate or deactivate the optional alarm system and/or to direct thetransmitter to transmit at a higher rate.

Calibration data may be obtained in a variety of ways. For instance, thecalibration data may simply be factory-determined calibrationmeasurements which can be input into the sensor control unit using thereceiver or may alternatively be stored in a calibration data storageunit within the sensor control unit itself (in which case a receiver maynot be needed). The calibration data storage unit may be, for example, areadable or readable/writeable memory circuit.

Calibration may be accomplished using an in vitro test strip (or otherreference), e.g., a small sample test strip such as a test strip thatrequires less than about 1 microliter of sample (for example FreeStyle®blood glucose monitoring test strips from Abbott Diabetes Care, Alameda,Calif.). For example, test strips that require less than about 1nanoliter of sample may be used. In certain embodiments, a sensor may becalibrated using only one sample of body fluid per calibration event.For example, a user need only lance a body part one time to obtain asample for a calibration event (e.g., for a test strip), or may lancemore than one time within a short period of time if an insufficientvolume of sample is firstly obtained. Embodiments include obtaining andusing multiple samples of body fluid for a given calibration event,where glucose values of each sample are substantially similar. Dataobtained from a given calibration event may be used independently tocalibrate or combined with data obtained from previous calibrationevents, e.g., averaged including weighted averaged, etc., to calibrate.In certain embodiments, a system need only be calibrated once by a user,where recalibration of the system is not required.

Alternative or additional calibration data may be provided based ontests performed by a doctor or some other professional or by the user.For example, it is common for diabetic individuals to determine theirown blood glucose concentration using commercially available testingkits. The results of this test is input into the sensor control uniteither directly, if an appropriate input device (e.g., a keypad, anoptical signal receiver, or a port for connection to a keypad orcomputer) is incorporated in the sensor control unit, or indirectly byinputting the calibration data into the receiver/display unit andtransmitting the calibration data to the sensor control unit.

Other methods of independently determining analyte levels may also beused to obtain calibration data. This type of calibration data maysupplant or supplement factory-determined calibration values.

In some embodiments of the invention, calibration data may be requiredat periodic intervals, for example, every eight hours, once a day, oronce a week, to confirm that accurate analyte levels are being reported.Calibration may also be required each time a new sensor is implanted orif the sensor exceeds a threshold minimum or maximum value or if therate of change in the sensor signal exceeds a threshold value. In somecases, it may be necessary to wait a period of time after theimplantation of the sensor before calibrating to allow the sensor toachieve equilibrium. In some embodiments, the sensor is calibrated onlyafter it has been inserted. In other embodiments, no calibration of thesensor is needed.

Analyte Monitoring Device

In some embodiments of the invention, the analyte monitoring deviceincludes a sensor control unit and a sensor. In these embodiments, theprocessing circuit of the sensor control unit is able to determine alevel of the analyte and activate an alarm system if the analyte levelexceeds a threshold. The sensor control unit, in these embodiments, hasan alarm system and may also include a display, such as an LCD or LEDdisplay.

A threshold value is exceeded if the datapoint has a value that isbeyond the threshold value in a direction indicating a particularcondition. For example, a datapoint which correlates to a glucose levelof 200 mg/dL exceeds a threshold value for hyperglycemia of 180 mg/dL,because the datapoint indicates that the user has entered ahyperglycemic state. As another example, a datapoint which correlates toa glucose level of 65 mg/dL exceeds a threshold value for hypoglycemiaof 70 mg/dL because the datapoint indicates that the user ishypoglycemic as defined by the threshold value. However, a datapointwhich correlates to a glucose level of 75 mg/dL would not exceed thesame threshold value for hypoglycemia because the datapoint does notindicate that particular condition as defined by the chosen thresholdvalue.

An alarm may also be activated if the sensor readings indicate a valuethat is beyond a measurement range of the sensor. For glucose, thephysiologically relevant measurement range is typically 30-400 mg/dL,including 40-300 mg/dL and 50-250 mg/dL, of glucose in the interstitialfluid.

The alarm system may also, or alternatively, be activated when the rateof change or acceleration of the rate of change in analyte levelincrease or decrease reaches or exceeds a threshold rate oracceleration. For example, in the case of a subcutaneous glucosemonitor, the alarm system might be activated if the rate of change inglucose concentration exceeds a threshold value which might indicatethat a hyperglycemic or hypoglycemic condition is likely to occur.

A system may also include system alarms that notify a user of systeminformation such as battery condition, calibration, sensor dislodgment,sensor malfunction, etc. Alarms may be, for example, auditory and/orvisual. Other sensory-stimulating alarm systems may be used includingalarm systems which heat, cool, vibrate, or produce a mild electricalshock when activated.

Drug Delivery System

The subject invention also includes sensors used in sensor-based drugdelivery systems. The system may provide a drug to counteract the highor low level of the analyte in response to the signals from one or moresensors. Alternatively, the system may monitor the drug concentration toensure that the drug remains within a desired therapeutic range. Thedrug delivery system may include one or more (e.g., two or more)sensors, a processing unit such as a transmitter, a receiver/displayunit, and a drug administration system. In some cases, some or allcomponents may be integrated in a single unit. A sensor-based drugdelivery system may use data from the one or more sensors to providenecessary input for a control algorithm/mechanism to adjust theadministration of drugs, e.g., automatically or semi-automatically. Asan example, a glucose sensor may be used to control and adjust theadministration of insulin from an external or implanted insulin pump.

Each of the various references, presentations, publications, provisionaland/or non-provisional U.S. patent applications, U.S. patents, non-U.S.patent applications, and/or non-U.S. patents that have been identifiedherein, is incorporated herein by reference in its entirety.

Other embodiments and modifications within the scope of the presentdisclosure will be apparent to those skilled in the relevant art.Various modifications, processes, as well as numerous structures towhich the embodiments of the invention may be applicable will be readilyapparent to those of skill in the art to which the invention is directedupon review of the specification. Various aspects and features of theinvention may have been explained or described in relation tounderstandings, beliefs, theories, underlying assumptions, and/orworking or prophetic examples, although it will be understood that theinvention is not bound to any particular understanding, belief, theory,underlying assumption, and/or working or prophetic example. Althoughvarious aspects and features of the invention may have been describedlargely with respect to applications, or more specifically, medicalapplications, involving diabetic humans, it will be understood that suchaspects and features also relate to any of a variety of applicationsinvolving non-diabetic humans and any and all other animals. Further,although various aspects and features of the invention may have beendescribed largely with respect to applications involving partiallyimplanted sensors, such as transcutaneous or subcutaneous sensors, itwill be understood that such aspects and features also relate to any ofa variety of sensors that are suitable for use in connection with thebody of an animal or a human, such as those suitable for use as fullyimplanted in the body of an animal or a human. Finally, although thevarious aspects and features of the invention have been described withrespect to various embodiments and specific examples herein, all ofwhich may be made or carried out conventionally, it will be understoodthat the invention is entitled to protection within the full scope ofthe appended claims.

The following examples are put forth so as to provide those of ordinaryskill in the art with a complete disclosure and description of how tomake and use the embodiments of the invention, and are not intended tolimit the scope of what the inventors regard as their invention nor arethey intended to represent that the experiments below are all or theonly experiments performed. Efforts have been made to ensure accuracywith respect to numbers used (e.g., amounts, temperature, etc.) but someexperimental errors and deviations should be accounted for. Unlessindicated otherwise, parts are parts by weight, molecular weight isweight average molecular weight, temperature is in degrees Centigrade,and pressure is at or near atmospheric.

EXAMPLES Sensors having Sensing Layers Incorporating a High-BoilingPoint Solvent

FIGS. 6A and 6B illustrate problems that may be associated with sensormembrane fabrication. FIG. 6A shows a microphotograph of a control spot(i.e., no high-boiling point solvent) of a sensing layer formulation.FIG. 6A shows the so-called “coffee ring” effect which results in pooruniformity and/or distribution of one or more components of the sensinglayer of a sensor (e.g., an enzyme-containing sensing layer of suchdevices). In order to address these issues a high-boiling point solventwas incorporated into the sensing layer of the sensor. FIG. 6B shows aprofilometer graph of a control spot of a sensing layer that does notinclude a high-boiling point solvent.

In a comparison between a sensing layer formulation deposited on a goldsubstrate in which the sensing layer formulation was not supplementedwith a high-boiling point solvent and a sensing layer formulationdeposited on a gold substrate in which a sensing layer formulation thatwas treated with a high-boiling point solvent, the high-boiling pointsolvent-treated sensing layer is smoother, more homogenous and uniformin distribution as compared to the sensing layer lacking thehigh-boiling point solvent (see FIGS. 6A and 6B). For example, FIGS. 7Aand 7B illustrate a sensing layer that included 5% (w/v) ethylene glycoland the corresponding profilometer graph, respectively. In addition,FIGS. 8A and 8B illustrate a sensing layer that included 15% (w/v)ethylene glycol and the corresponding profilometer graph, respectively.Supplementing the sensing layer formulation with a high-boiling pointsolvent resulted in an improved sensing layer coating that eliminated alack of uniformed distribution and the “coffee ring” effect shown inFIGS. 6A and 6B.

When FIGS. 6A and 6B are juxtaposed against FIGS. 7A, 7B, 8A and 8B,they provide a comparison between a sensing layer formulation depositedon a gold substrate in which the sensing layer formulation was notsupplemented with a high-boiling point solvent (FIGS. 6A and 6B), versusa sensing layer formulation deposited on a gold substrate with a sensinglayer that was supplemented with the high-boiling point solvent ethyleneglycol, (FIGS. 7A, 7B, 8A and 8B).

In addition, as evidenced by FIGS. 9A, 9B, 10A, 10B, 11A, and 11B,treatment with different high-boiling point solvents, such as diethyleneglycol monomethyl ether (FIGS. 9A, 9B, 10A and 10B) and dimethylsulfoxide (FIGS. 11A and 11B) also resulted in a sensing layer that wassmoother, more homogenous and more uniform in distribution as comparedto a control formulation that was not supplemented with a high-boilingpoint solvent (FIGS. 6A and 6B). FIGS. 9A and 9B illustrate a sensinglayer that included 3% (w/v) diethylene glycol monomethyl ether and thecorresponding profilometer graph, respectively. FIG. 9B shows aprofilometer graph of the cross-sectional profiles of three sensinglayer spots that included 3% (w/v) diethylene glycol monomethyl ether.FIGS. 10A and 10B illustrate a sensing layer that included 20% (w/v)diethylene glycol monomethyl ether and the corresponding profilometergraph, respectively. FIG. 10B shows a profilometer graph of thecross-sectional profiles of four sensing layer spots that included 20%(w/v) diethylene glycol monomethyl ether. FIGS. 11A and 11B illustrate asensing layer that included 5% (w/v) dimethyl sulfoxide and thecorresponding profilometer graph, respectively.

Sensing layers that included different concentrations of high-boilingpoint solvents are also shown in FIGS. 12A-12D, 13A-13D, 14A-14B, and15A-15D. FIGS. 12A-12D show a sensing layer that included 5% (w/v)diethylene glycol monomethyl ether (FIG. 12A), 10% (w/v) diethyleneglycol monomethyl ether (FIG. 12B), 15% (w/v) diethylene glycolmonomethyl ether (FIG. 12C), and 20% (w/v) diethylene glycol monomethylether (FIG. 12D). FIGS. 13A-13B show a sensing layer that included 1%(w/v) ethylene glycol and the corresponding profilometer graph,respectively. FIGS. 13C-13D show a sensing layer that included 3% (w/v)ethylene glycol and the corresponding profilometer graph, respectively.FIGS. 14A-14B show a sensing layer that included 1% (w/v) diethyleneglycol monomethyl ether and the corresponding profilometer graph,respectively. FIGS. 15A-15B show a sensing layer that included 1% (w/v)dimethyl sulfoxide and the corresponding profilometer graph,respectively. FIGS. 15C-15D show a sensing layer that included 3% (w/v)dimethyl sulfoxide and the corresponding profilometer graph,respectively.

In certain embodiments, sensing layers that include a high-boiling pointsolvent maintain their smooth, homogenous and uniform distribution evenafter the sensing layer is subsequently washed. FIGS. 16A-16C showpost-wash microphotographs of sensing layers that included 5% (w/v)ethylene glycol (FIG. 16A), 5% (w/v) diethylene glycol monomethyl ether(FIG. 16B), and 5% (w/v) dimethyl sulfoxide (FIG. 16C).

FIG. 17 shows graphs of one-way analysis of variance (ANOVA) ofsensitivity/slope (nA/mM) for sensing layer formulations that includedvarying concentrations of high-boiling point solvents, e.g., 5% (w/v)ethylene glycol, 15% (w/v) ethylene glycol, 5% (w/v) diethylene glycolmonomethyl ether, and 15% (w/v) diethylene glycol monomethyl ether. Asdemonstrated in FIG. 17, the high-boiling point solvent supplementedsensing layers sensors had similar sensitivities. One-way ANOVA data isshown in Table 2 below.

TABLE 2 Summary of Fit Rsquare 0.365455 Adj Rsquare 0.265264 Root MeanSquare Error 0.084579 Mean of Response 0.507087 Observations (or SumWgts) 23 Analysis of Variance Source DF Sum of Squares Mean Square FRatio Prob > F Lot 3 0.07827964 0.026093 3.6476 0.0313 Error 190.13591819 0.007154 C. Total 22 0.21419783 Means for One-Way ANOVA StdLower Upper Level Number Mean Error 95% 95% 15% DEG 2 0.607500 0.059810.48232 0.73268 15% EG 7 0.440000 0.03197 0.37309 0.50691 5% DEG 50.578800 0.03782 0.49963 0.65797 5% EG 9 0.497111 0.02819 0.438100.55612 Standard error used a pooled estimate of error variance.

FIG. 18 shows graphs of one-way ANOVA of average response time (sec) forsensing layer formulations that included varying concentrations ofhigh-boiling point solvents, e.g., 5% (w/v) ethylene glycol, 15% (w/v)ethylene glycol, 5% (w/v) diethylene glycol monomethyl ether, and 15%(w/v) diethylene glycol monomethyl ether. As demonstrated in FIG. 18,the high-boiling point solvent supplemented sensing layers sensors hadsimilar average response times. One-way ANOVA data is shown in Table 3below.

TABLE 3 Summary of Fit Rsquare 0.212204 Adj Rsquare 0.087815 Root MeanSquare Error 50.24996 Mean of Response 385.4022 Observations (or SumWgts) 23 Analysis of Variance Source DF Sum of Squares Mean Square FRatio Prob > F Lot 3 12923.029 4307.68 1.7060 0.1996 Error 19 47976.1082525.06 C. Total 22 60899.137 Means for One-Way ANOVA Std Lower UpperLevel Number Mean Error 95% 95% 15% DEG 2 369.925 35.532 295.56 444.2915% EG 7 361.250 18.993 321.50 401.00 5% DEG 5 373.090 22.472 326.05420.13 5% EG 9 414.467 16.750 379.41 449.52 Standard error used a pooledestimate of error variance.

In conclusion, the experiments above show that the addition of one ormore high-boiling point solvents to an analyte sensor formulation, suchas a sensing layer, promoted the uniformity and/or distribution of oneor more components of the membrane formulation and elimination of the“coffee ring” effect of settling of sensing layer components at theperimeter of the formulation on the sensor surface.

1-57. (canceled)
 58. An electrode structure, comprising a conductivematerial; and an enzyme formulation disposed on a surface of theconductive material, wherein the enzyme formulation comprises polymer,enzyme, and a high-boiling point solvent at a concentration of up to 5%(w/v) of the total formulation of the enzyme formulation.
 59. Theelectrode structure of claim 58, wherein the enzyme formulation has asubstantially arcuate profile as measured using a profilometer.
 60. Theelectrode structure of claim 58, further comprising a membrane disposedover the enzyme formulation.
 61. The electrode structure of claim 58,wherein the high-boiling point solvent comprises a bivalent alcohol, abivalent alcohol alkyl ether, a bivalent alcohol dialkyl ether, or apolar aprotic solvent.
 62. The electrode structure of claim 58, whereinthe high-boiling point solvent is ethylene glycol, diethylene glycolmonomethyl ether, diethylene glycol dimethyl ether, or dimethylsulfoxide.
 63. The electrode structure of claim 58, wherein thehigh-boiling point solvent comprises ethylene glycol.
 64. The electrodestructure of claim 58, wherein the high-boiling point solvent comprisesdimethyl sulfoxide.
 65. The electrode structure of claim 58, wherein thehigh-boiling point solvent comprises diethylene glycol monomethyl ether.66. The electrode structure of claim 58, wherein the enzyme is aglucose-responsive enzyme.
 67. The electrode structure of claim 58,wherein the enzyme formulation further comprises a redox mediator. 68.The electrode structure of claim 58, wherein the redox mediatorcomprises a ruthenium-containing complex or an osmium-containingcomplex.
 69. The electrode structure of claim 67, wherein the redoxmediator or the enzyme is covalently bonded to the polymer.
 70. Theelectrode structure of claim 58, wherein the membrane is a polymericmembrane.
 71. The electrode structure of claim 58, wherein the membranelimits the flux of analyte to the enzyme formulation.
 72. The electrodestructure of claim 58, wherein the membrane is covalently bonded to theenzyme formulation.
 73. The electrode structure of claim 58, wherein themembrane is cross-linked to the enzyme formulation.